Question about Coleman Powermate Premium Plus 6250W Portable Generator

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Can you advise more on coil/windings vs brushes shorting out?

Marine generator power source... westerbeke 5kw, gas, was running well... began to slow start, when in a pinch i did short the starter to get started, no obvious cause/effect to this however the last time I started it, I noticed some smoke and shut it down quickly... one dockside mechanic said it was a coil short , yet claimed this as the issue with little diagnosis or once over examination... then when given a quote for this fix... ouch!, my passing alarm of the snap determination suddenly became more uncertain as to its truth or accuracy. How can generator symtoms be read... issue be troubleshot? Apart from a starter and a new zinc or two, up to that day, was all I assumed it needed sooner rather than later? anyone? any ideas>

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Your dockside mechanic is likely correct. The field coils have likely shorted. And yes, they can be WAY expensive to replace. The snap decision was likely based on what you told him at the time the smoke started and lack of anything else that was burned (or you would have said something about it). It is also fairly common for starters on these monsters (westerbe, kohler, onan, etc) to fail due to the harsh environments they are installed in. I have yet to work in a bilge are that didn't have at least an oil mark 12inches up the bulkhead....

But, if you are able to get at the starter yourself, there might be an easier way out.

Pull the starter out, and take it to local starter / alternator rebuild shop. See what they are able to do with it. It might cost you few dollars for them to take a look at it to see if they are even able to rebuild it, but I would think that it would be worth the gamble. Try it and see what happens. If the starter is fine, it would be a good time to have the commutators cleaned up and brushes replaced. Do the bearings too, just because you can.

Oh, and if all you have replaced is just anodes, then you are headed for another disaster. You should be checking and replacing the impellers as well, about every couple years, give or take depending on waters that you frequent.

I always recommend to my clients that they carry a consumable spares kits (oil, filters, limit switches, impellers, fuses, etc). I hope you have one too.

Posted on Sep 15, 2009


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Need wiring diagram,from alternator to plug-ins for briggs & Stratton (3500) Elite series Model # 030208-0

No wiring diagram available from Briggs. Try re-magnetizing the rotor. No AVR or Capacitor listed in the parts list.

Disconnect the wires to brushes ( pay attention to the order) and apply 12vdc to brushes. Positive goes to brush closest to the bearing. Start the generator and check for output. If output is normal run the unit a few minutes to ensure re-magnetization then shut down normally. After shut down disconnect the 12 vdc source and re-install the previous disconnected wires. Now re start the generator and test for output should be okay provide there is no problems with the alternator. If no output during the above re-magnetization then your rotor windings my burned out.

Oct 10, 2014 | Briggs & Stratton Gas Powered 3500-4375...


Generator Not Producing Power - Field Winding

There are 4 requirements that have to be met before a generator is able to produce power. Due to number of questions that have been asked, a Coleman PowerMate 1500-1850 with a Briggs and Stratton Engine will be used here.

1) The Engine has to be turning at correct speed
2) Field Winding (Rotor) on the alternator must be energized
3) AC Winding (Stator) must create a voltage in presence of magnetic field
4) Output passes through Safety Devices before it reaches an outlet.

This Tip will cover the Field Winding.

The alternator of the generator is similar to the alternator in your vehicle. A current flows through the field winding, and creates a magnetic field. This magnetic field is rotated (by the engine), and the magnetic lines of force cut through the many coils of wire that are located in the stator.

First things first though. Lets see if the field winding (aka rotor) is any good. You will first have to disassemble the generator / alternator to get to the brushes. The brushes are how the current flows from the regulator, and into the rotor while it is spinning. Look closely, and you will see 2 rings on the rotor. Each ring is the end of the coil of wire that makes up the rotor. Using a multimeter, check for resistance between the rings, but make sure that you don't scratch or gouge them. You should have some kind of continuity here, compare your readings against what is published in the service manual. Also check each ring to the core or rod of the rotor as well. There should NOT be any continuity at all. If there is, this indicates a grounded rotor, and will have to be rewound (starter / alternator shop) or replaced.

Look at the brushes and brush holder assembly. Take a measurement of the length of each brush, and compare it to the minimum length in the service manual. If the brush is too short, or shows signs of overheating, shock, or otherwise, replace the brushes. If the brush holder is also darkened or burnt, it will also need to be replaces as well.

From the brush holder, follow the wires to the voltage regulator. In most low end generators, this is merely a capacitor that samples output voltage, and feeds it back into the rotor. There should also be a diode here as well. Again, using your multimeter, check the diode to see if it is open or shorted. If your meter has a diode check function, use it. Otherwise, check the diode using the resistance scale. You should have a resistance in direction, and infinite (open) in the other. If you have resistance in both directions, or infinite in both directions, then the diode is bad and will need to be replaced. Some meters will have a capacitor check, but the capacitor in the generator will likely be too large for this to work. Look for signs that the capacitor may be bad. Bulging, leaking, damaged terminals all indicate replacement is needed.

On generators that have an actual voltage regulator, you will need to consult the service manual for steps to check the regulator. Usually, regulators are not easily tested, and are replaced when other potential problems have been ruled out.

If a generator has sat for a long time, it may have lost its residual magnetism. When the engine is not turning, there remains a small magnetic field due to the properties of the iron / steel rotor core. It is possible that this field has dissipated over time. You can temporarily reestablish this field through a process called "Flashing." Basically, it involves connecting a lantern-type of battery between one of the brushes, and the core of the rotor. Consult your owners manual for the exact and recommended procedure.

If the field winding is testing good, its time to move onto the next tip:
Stator Winding.

on Jul 15, 2010 | Electrical Supplies

1 Answer

Coleman 3500 with subaru engine no power to outlets

Hello there.
I'm assuming that engine runs fine. if there's no power output then the AVR or carbon brushes are dead. remove the back cover of the alternator very carefully and look at the center to find the rotor rings and check if the plastic brush holder hasn't melt or heat deformed and make sure the brushes make good contact against the rotor rings. if everything's fine then the AVR is dead. The AVR is a crescent shaped plastic container similar to this one.
replace it with any similar found on Ebay, just make sure that connectors and cables are similar in shape and number. Regards

Jul 06, 2014 | Husky 3650 Watt Generator with Subaru...

1 Answer

Voltage shows 80 on 110v and 155 on 240v

if you take the end of the generator off you will see a rectifier or four diodes with a varister or a full wave brige rectifier, sounds like you have a bad diode, or a shorted exite winding to the rotor, the exite winding is a small turn winding feeds the rectifier board that ac signal is converted to dc to feed the rotor ,the rotor produces a magnetic field which rotates inside the stator windings , the magnetic lines of flux from this field cut through thre stator winding inducing a voltage in the stator coils. hope this helps

May 27, 2011 | Dewalt DG6000 Heavy Duty 6000 Watt Gas...

1 Answer

Coleman powermate generator has no output. have changed diodes, capacitor and brushes. i have 12 volts across the brushes but no output at the receptacles. coleman powermate 0545005 5000w

Disconnect the leads going to the brushes, and check for continuity (resistance) of the field winding. You should be able to measure *something* on the order of a few ohms. If you have resistance, then check each brush contact to the shaft that the field winding is on. There should not be any resistance at all, if there is, you have a shorted field winding and will need to be replaced.

Check the resistance of the stator winding next, make sure that nothing is connected to the generator, disconnect the stator wires if you are able (label them!). Check for resistance between the leads (2 wires for a 2 pole, 4 wires for a 4 pole). If there is no resistance, then the stator is open, and will need to be replaced. Also check for resistance from each wire to the frame of the alternator, there should not be any resistance here (indicating a shorted stator). If there is, then you have a shorted stator, and will need to have it replaced.

Replacement is likely to be impractical, probably cheaper to buy another generator with the same engine and keep the old engine as a spare. Still, contact an automotive starter / alternator shop for prices.

Feb 07, 2011 | Electrical Supplies

1 Answer

The circut board on my 6250 blew apart so i replaced it do i need to polarize it because i still have no voltage

I have seen this often, somtimes the circuit/s that power the board will burn out. Usually happens when using generator for powering large air comperssors or equipment that use capacitors. One circuit powers the board, some generators have a second winding for measuring voltage for regulator function. Service center will give you required ohm reading for both windings. For estimate only reading may be between 6 and 9 ohm. Also check that windings are not open or short to ground. Check polarity of brushes, you cannot swap wires to brushes. Circuit board should have come with instruction sheet for wiring. Good luck and post again if you have more questions.

Jul 02, 2010 | Coleman Powermate Premium Plus 6250W...

5 Answers

No AC out put

After working on several of this style coleman generator,i have found that the lead wires in the windings that are soldered to where your brushes would contact tend to break.I don't know if it's a poor design or just a fluke,i would check to see if your getting continuity on the rotor and go from there.They seem to either "burn off" or just break.

Mar 09, 2010 | Coleman Powermate Powermate 5000W...

1 Answer

Suzuki SE4000SED generator with no output

There was a day and time when generators were simple. There were no capacitors, regulators to control/adjust power to magnet or ground fault outlets. Winding getting hot indicates short, however could be bad capacitors. Rectifiers and capacitors must be removed from circuit to test properly. Here is a simple test that I use to find fault area. I use a small power supply (16v AC 1 amp like doorbell transformer) into the 110v outlet of generator. This should energize the armature magnet and actually produce voltage at commutator with brushes pulled off. You can slowly pull the starter rope to move the armature into a different positon the voltage will vary. If the ac windings are shorted there will be very little or no magnet. There is a seperate 110 v circuit at the 220v outlet to test (there are two 110v windings that make up the 220v outlet, one is also used for the 110v outlet). There is another winding that products voltage for the regulator that powers the magnet thru the brushes but I think that circuit is porbably working because of the heat in the windings. You might even have 110v power at the 220v outlet. As our parents told us over and over, be careful when working with electricity. Enjoy

Dec 06, 2008 | Electrical Supplies

1 Answer

Powermate PM0496500.02 No voltage output

Here is a simple test to check field and other wiring. With engine off apply 12v ac 1 amp to 110v outlet plug on generator. This will energize the field windings and should cause the armature to produce dc voltage at the brushes and produce a nice magnet. If there is a short in the field or broken wire or shorted capacitor there will be no dc reading at the brushes. . This test is the opposite of what actually occurs when the engine is running. That is the armature produces a magnet fed thru the windings, regulator and brushes. If dc voltage is present at the burshes, remove 12v ac and start engine to check for output. enjoy

Oct 23, 2008 | Coleman Powermate Premium Plus 6250W...

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